Reciprocating saw

ABSTRACT

An reciprocating saw comprising a housing, a motor, a spindle movably supported within said housing and having a front end adapted to support a saw blade, a drive assembly, and an adjustable shoe assembly. The adjustable shoe assembly includes a shoe, a shoe support member pivotally supporting the shoe, a locking member pivotally supported by the housing, and a lever connected to the locking member.

RELATED APPLICATIONS

The present application is a division of U.S. application Ser. No.09/133,728, filed Aug. 13, 1998 now U.S. Pat. No. 6,249,979.

BACKGROUND OF THE INVENTION

The present invention generally relates to reciprocating saws.

Reciprocating saws are used to cut a variety of objects made from avariety of materials, such as metal pipes, wood and dry wall. Such sawsgenerally include a housing and a spindle mounted in the housing forreciprocating motion along an axis that is parallel to the longitudinalextent of the spindle. An electric motor provides power to the spindlethrough a mechanical reciprocating device that converts the rotarymotion of a motor shaft to reciprocating motion. Such mechanicalreciprocating devices can, for example, include an eccentric drive, asdisclosed in U.S. Pat. No. 5,079,844, or a wobble plate drive, asdisclosed in U.S. Pat. Nos. 5,025,562 and 5,050,307. In a typical wobbleplate drive, the drive arm of a primary wobble plate has a spherical tipthat engages a suitable bore defined in the reciprocating spindle. Thedrive can also include a secondary wobble plate having a drive arm witha spherical tip engaging a bore defined in a reciprocatingcounterweight.

In some reciprocating saws, the spindle reciprocates in an orbitalmotion, as opposed to a straight line reciprocating motion. The orbitalmotion is commonly characterized by a forward (i.e., in the cuttingdirection) motion of the saw blade as the saw blade is being retractedtoward the saw on the cutting stroke, and a corresponding rearward(i.e., opposite the cutting direction) motion of the saw blade as thesaw blade is being extended away from the saw on the return stroke. Theresult is a circuitous, or orbital, path of the saw blade. Such orbitalmotion is believed to improve the speed at which the saw cuts aworkpiece by driving the saw blade into the workpiece during the cuttingstroke and withdrawing the saw blade from the workpiece during thereturn stroke.

Orbital motion has been achieved in a number of different ways. Forexample, in U.S. Pat. Nos. 4,238,884 and 4,628,605, a forward force (inthe cutting direction) is applied by a blade roller directly to the sawblade during the cutting stroke, and forward motion of the saw blade isaccommodated by a forgiving interconnection between the spindle and thedrive mechanism. In U.S. Pat. No. 5,212,887, the spindle reciprocatesthrough a pivotally-mounted bushing, and the back end of the spindle isconnected to an eccentric member that provides forward-rearward motionto the spindle. In U.S. Pat. Nos. 4,962,588 and 4,550,501, the back endof the spindle is moved forward-rearward by connection to a cam surfaceon a rotating gear. In U.S. Pat. No. 5,392,519 the back end of thespindle is moved forward-rearward by connection to an eccentric memberformed on the drive gear.

In some orbital reciprocating saws, the orbital motion of the saw bladecan be adjusted or disengaged. For example, U.S. Pat. No. 4,550,501discloses a cam lever located on the side of the saw and operable toadjust the orbital motion of the saw blade. The cam lever is adjustedbetween a first position, in which the spindle is connected to the camsurface on the rotating gear, and a second position, in which thespindle is disconnected from a portion of the cam surface on therotating gear.

To accommodate the orbital motion of the spindle, an orbitalreciprocating saw typically includes a bearing arrangement forsupporting the spindle. For example, U.S. Pat. No. 4,550,501 discloses abearing block and a slidable bearing insert received within the bearingblock. The bearing insert and the bearing block are dimensioned toprovide a clearance space in the vertical direction to permit limitedrelative movement between the bearing insert and the bearing block toaccommodate the orbital motion. A separate dust seal is mountedforwardly of the bearing assembly to prevent debris and othercontamination from entering the saw housing.

In U.S. Pat. No. 5,212,887, an annular bearing member slidably receivesthe spindle or plunger assembly of the reciprocating saw. The bearing isreceived within an annular support mounted on the tool casing. Thebearing and the bracket define spaces for receiving O-rings andclearance spaces. The O-rings and the clearance spaces cooperate toprovide a swivel or swinging mounting for the plunger assembly to permitoscillatory movement of the plunger assembly. In other bearingarrangements, a spherical bearing may be provided, such as that shown inU.S. Pat. No. 3,945,120.

Some reciprocating saws further include a shoe secured relative to thehousing to provide a flat surface for resting against the workpieceduring cutting operations. The shoe is positioned near the saw blade,and the flat surface is usually perpendicular to the saw blade. The shoetypically includes an opening through which the blade extends.

In some reciprocating saws, the shoe may be adjustable relative to thelength of the saw blade so that the shoe may be located in an optimumposition for cutting operations. U.S. Pat. No. 5,421,091 discloses anadjustable guideshoe for a reciprocating saw. The adjustable guideshoeis mounted on a support bar which is received within an elongated slotformed in the nose section of the saw housing. The support bar includesa plurality of sets of opposed cam faces which are provided inside-by-side pairs spaced longitudinally along the bar. A manuallyoperated plunger is mounted in the nose section and is spring biasedtoward the support bar. The plunger bar includes cam surfaces adaptedfor complementary wedging engagement with selected sets of cam faces onthe support bar to achieve a self-locating function for the support andguideshoe mounted thereon.

SUMMARY OF THE INVENTION

The reciprocating saws described above have several independentproblems.

For example, in a reciprocating saw with a wobble plate drive, thewobble plate drive arm and the spindle bore are machined with tighttolerances to extend the life of the saw and also to maintain acceptablenoise levels. The required machining increases the cost of manufacturingthe saw. Also, as the joint between the wobble plate drive arm and thespindle bore wears, the tight tolerance of the joint is lost so thatwear of the saw increases. The loose joint between the drive arm and thespindle bore also causes increased noise.

One independent problem with a reciprocating saw having an orbital drivesystem in which cam member is fixed to the drive shaft is that the cammember is not replaceable or interchangeable without changing theattached drive shaft and/or drive gear. The lack of replaceability is aproblem because the cam member is subject to wear due to the pressureapplied during orbital cutting operations (i.e., when the saw blade isplunged into the workpiece). The lack of interchangeability is a problembecause another cam member having a different cam configuration mayprovide a preferred orbital path for the saw blade for a given cuttingoperation.

One independent problem with the adjustment of an orbital reciprocatingsaw is that previous orbital actuation levers are typically located onone side of the tool. As a result, the operator can only activate thelever from that side of the saw.

One independent problem with the bearing assemblies that accommodateorbital motion in a reciprocating saw is that the bearing assemblies aredifficult to assemble and increase the cost of manufacturing the saw.Another problem with some of these bearing assemblies is that they donot provide a good seal to prevent contaminants and debris from enteringthe saw housing.

One independent problem with some adjustable shoe assemblies forreciprocating saws is that these assemblies do not provide fineincrements of adjustment to allow the shoe to be placed in the optimalposition. Another problem with some of these adjustable shoe assembliesis that they require additional tools, such as a wrench or a key, foradjustment. Yet another problem with some of these shoe adjustmentassemblies is that the adjustment mechanism or lever is accessible fromonly one side of the saw so that the operator can use only one hand toactuate the adjustment lever. A further problem with some of these shoeadjustment assemblies is that, while the lever is biased towards alocked position, the lever may be inadvertently operated by grasping thefront portion of the housing, allowing the shoe to move relative to thehousing during cutting operations.

The present invention provides a reciprocating saw that attempts toalleviate one or more problems relating to existing reciprocating saws.In one aspect, the invention provides a reciprocating saw that drives asaw blade in an adjustable orbital path. The saw comprises a housing, amotor supported by the housing and including a drive shaft, a spindlemovably supported within the housing and having a front end adapted tosupport the saw blade through a cutting stroke and a return stroke, awobble plate mounted on the drive shaft and connected to the spindle toreciprocally drive the spindle relative to the housing upon rotation ofthe drive shaft, an orbital drive assembly connected to the spindle andoperable to selectively drive the saw blade in an orbital path, and anorbital adjustment assembly connected to the orbital drive assembly andoperable to adjust the orbital path of the saw blade.

Preferably, the orbital drive assembly includes a cam member removablysupported on the drive shaft. The cam member has an outer surface thatis eccentric relative to the drive shaft axis. The cam member isengageable with the spindle to cause orbital movement of the saw bladeupon rotation of the drive shaft.

The orbital drive assembly may further include a support memberpivotably supported by the housing. The spindle is supported within thesupport member for reciprocal movement relative to the support memberalong the support member axis. The orbital drive assembly may furtherinclude a cam follower selectively engageable with the outer surface ofthe cam member and engageable with the support member. During rotationof the drive shaft, engagement of the cam follower with the cam membercauses pivoting movement of the support member and orbital movement ofthe saw blade.

Preferably, the reciprocating saw further comprises a limiting portionengageable with the support member to limit pivoting movement of thesupport member in a direction perpendicular to the support member axis.Also, the orbital drive assembly preferably further includes a camfollower support member supported by the housing and providing thelimiting portion.

The orbital adjustment assembly may be operable to selectively disengagethe cam follower from the cam member during at least a portion of therotation of the cam member to change the orbital path of the saw blade.The orbital adjustment assembly may include an orbital adjustment membersupported by the housing for movement between a first position, in whicha portion of the orbital adjustment member engages a portion of the camfollower during the portion of the rotation of the cam member todisengage the cam follower from the cam member, and a second position.Preferably, the orbital adjustment member has a cylindrical outersurface defining an axis of rotation, and the orbital adjustment memberis rotatable about the axis between the first position and the secondposition.

The orbital adjustment assembly may further include a lever for movingthe orbital adjustment member between the first and second positions,and the lever is preferably positioned so that it is engageable throughthe upper portion of the housing. In this manner, the orbital adjustmentmember is adjustable from either side of the tool by an operator.

The saw may further comprise a spherical bearing assembly supported bythe housing. The spherical bearing assembly slidably supports thespindle for movement relative to the housing and supports the forwardportion of the support member so that the support member and the spindleare pivotable relative to the housing. Preferably, the spherical bearingassembly includes a spherical sleeve supported between the housing andthe support member and a bearing member supported between the supportmember and the spindle.

In another aspect, the invention provides a reciprocating saw having anadjustable shoe assembly. The shoe assembly includes a shoe for engaginga surface of the workpiece and a shoe support member supporting theshoe. The shoe support member is movably supported by the saw housingand defines a plurality of teeth along its length.

The shoe assembly also includes a locking member pivotally supported bythe saw housing. The locking member defines a slot. The shoe assemblyalso includes a lever for pivoting the locking member between a lockedposition, in which the teeth are prevented from moving in the slotdefined by the locking member so that the shoe support member isprevented from moving relative to the housing, and a release position,in which the teeth are movable in the slot so that the shoe supportmember is movable relative to the housing.

Preferably, the lever is operable from the lower portion of the sawhousing so that it can be engaged by either hand of the operator. Also,during cutting operations, the operator preferably engages the lever sothat the locking member is maintained in the locked position.

In yet another aspect, the invention provides a drive assembly for areciprocating saw. The drive assembly comprises a spindle movablysupported within the saw housing and defining a bore, a wobble platemounted on the motor drive shaft and connected to the spindle toreciprocally drive the spindle relative to the saw housing upon rotationof the drive shaft, the wobble plate including a drive arm having an endreceivable in the bore, and a wear compensating member positioned in thebore and engageable with the end of the drive arm. The drive assemblythus provides a wear compensating socket between the spindle and thedrive arm of the wobble plate. Preferably, the wear compensating memberis a spring.

One independent advantage of the present invention is that, because awear compensating socket is provided in the spindle, the tolerance ofthe joint between the drive arm of the wobble plate and the spindle boredoes not have to be as tightly machined. This reduces the cost ofmanufacturing the saw. Additionally, the wear compensating socketadjusts for wear between the drive arm and the spindle bore extendingthe life of the saw and reducing the noise level of the saw.

Another independent advantage of the present invention is that becausethe cam member is separate from the drive shaft, the cam member can beeasily replaced or interchanged. This provides easy replacement of aworn cam member or interchangeability with different cam members tochange the pattern of the orbital blade movement to affect the cuttingperformance of the reciprocating saw.

Yet another independent advantage of the present invention is thatbecause the orbital actuation assembly is positioned at the top andcenter of the tool, the actuation assembly is operable with either hand.Further, the orbital actuation assembly maintains its center at thespindle axis allowing the orbital actuation lever to seal the openingthrough which the lever extends from the housing. In addition, becausethe orbital adjustment member or lock-out plate lifts the cam followeroff of the cam member, the cam follower is prevented from rattlingduring reduced-orbit or no-orbit cutting operations. Also, the orbitalactuation assembly provides multiple positions so that the amount oforbit in the path of the saw blade can be adjusted for different cuttingoperations.

A further independent advantage of the present invention is that thespherical bearing assembly allows the spindle to pivot freely duringorbital cutting operations. Also, the bearing assembly provides a goodseal that moves with the spindle to prevent dust and contamination fromentering the housing. Additionally, the bearing assembly allows easyassembly of the reciprocating saw.

Another independent advantage of the present invention is that theadjustable shoe assembly allows finer increments of adjustment of theshoe relative to the housing. Also, the adjustable shoe assembly doesnot require additional tools for adjustment of the shoe. Further, thelever is operable from either side of the tool with one hand. Inaddition, during cutting operations, the lever is held by the operatorin the locked position to reduce the chance of inadvertent unlocking ofthe shoe.

Other independent features of the invention will become apparent tothose skilled in the art upon review of the following detaileddescription, claims and drawings.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a reciprocating saw embodying the invention.

FIG. 2 is a partial cross-sectional side view of the reciprocating shownin FIG. 1.

FIG. 3 is an exploded perspective view of the orbital adjustmentassembly of the reciprocating saw shown in FIG. 1.

FIG. 4A is a partial cross-sectional view generally taken along line 4—4in FIG. 2 and illustrating the orbital drive assembly and the orbitaladjustment assembly in a full-orbit position.

FIG. 4B is a view similar to that in FIG. 4A and illustrating theorbital drive assembly and the orbital adjustment assembly in areduced-orbit position.

FIG. 5 is a partial cross-sectional side view of the orbital driveassembly and the orbital adjustment assembly.

FIG. 6 is an exploded perspective view of the spindle, support memberand bearing assembly of the reciprocating saw shown in FIG. 1.

FIG. 7 is a perspective view of a portion of the spindle shown in FIG.6.

FIG. 8 is an exploded perspective view of the adjustable shoe assemblyof the reciprocating saw shown in FIG. 1.

FIG. 8A is a perspective view of an alternative embodiment of a portionof the adjustable shoe assembly shown in FIG. 8.

FIG. 9 is a partial cross-sectional side view of the adjustable shoeassembly shown in FIG. 8 and illustrating the locking member in anunlocked position.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A reciprocating saw 10 embodying the present invention is illustrated inFIG. 1. The reciprocating saw 10 generally includes a main housing 14having an operator's handle 18, a forward portion 22 opposite the handle18, and an upper portion 26.

An electric motor 30 is supported by the housing 14. The motor 30includes a drive pinion 34 that engages a gear 38 mounted on a driveshaft 42. The drive shaft 42 is rotatably mounted within the housing 14.A drive hub 44 is mounted on the drive shaft 42 and is connected to thegear 38. The hub 44 defines an off-center pocket 45. A switch 46 islocated in the operator's handle 18 for energizing the motor 30 torotate the drive shaft 42.

A spindle 50 (partially shown) is supported by the housing forreciprocating and pivoting movement (e.g., orbital movement) relative tothe housing 14. As shown in FIG. 2, the spindle 50 includes a front end54 that supports a saw blade 58, which is designed to cut in a cuttingdirection 62 (i.e., in the direction of the saw teeth) opposite anon-cutting direction 66. The spindle 50 generally reciprocates the sawblade 58 through a cutting stroke (usually toward the housing 14) and areturn stroke (usually away from the housing 14).

A counterweight 70 is supported by the housing 14 for reciprocating andpivoting movement (e.g., orbital movement) relative to the housing 14.The counterweight 70 provides a vibration-reducing force that at leastpartially counteracts the forces created by movement of the spindle 50and the saw blade 58.

The reciprocating saw 10 also includes (see FIG. 2) a reciprocatingdrive assembly for driving the spindle 50 and the counterweight 70. Inthe illustrated construction, the reciprocating drive assembly includesa wobble plate drive assembly having a wobble shaft 74 positioned overthe drive shaft 42, and primary and secondary wobble plates 78 and 82that are driven by the wobble shaft 74 in a conventional manner.

The primary wobble plate 78 includes a primary drive arm 86 having aball end 90. The drive arm 86 extends through a slot 94 in thecounterweight 70 so that the end 90 extends into a bore 98 defined inthe spindle 50 to form a spindle socket. In this manner, the primarywobble plate 78 drivingly engages the spindle 50 for reciprocatingmovement.

The secondary wobble plate 82 includes a drive arm 102 having a ball end106 (see FIG. 1) that extends into a bore 110 (see FIG. 2) defined inthe counterweight 70 to form a counterweight socket. In this manner, thesecondary wobble plate 82 drivingly engages the counterweight 70 forreciprocating movement.

As shown in FIGS. 2, 6, and 7, the illustrated spindle 50 includes awear compensating member in the form of a spring 114 positioned in theforward portion of the bore 98. As shown in FIG. 2, the end 90 of theprimary wobble plate 78 engages the spring 114 so that a relativelytight fit is formed in the spindle socket between the end 90 and thebore 98. This tight fit reduces wear on the spindle 50 and primarywobble plate 78 and also reduces noise caused by a loose fit betweenthese components. Additionally, over the life of the reciprocating saw10, the spring 114 compensates for any wear in the spindle socketbetween the spindle 50 and the primary wobble plate 78 to maintain atight fit. In other constructions (not shown), a spring could similarlybe used in the counterweight socket between the end 106 of the secondarywobble plate 82 and the bore 110 of the counterweight 70.

The reciprocating saw 10 also includes (see FIGS. 2-5) an orbital driveassembly for driving the spindle 50 in an orbital motion (e.g.,reciprocating and pivoting motion). The orbital motion is characterizedby a forward (i.e., in the cutting direction 62) motion of the saw blade58 as the saw blade 58 is being retracted toward the saw housing 14 onthe cutting stroke, and a corresponding rearward (i.e., in thenon-cutting direction 66) motion of the saw blade 58 as the saw blade 58is being extended away from the housing 14 on the return stroke. Thisresults in a circuitous or orbital path of the saw blade 58.

The orbital drive assembly includes cam member 118 supported on thedrive shaft 42 for rotation with the drive shaft 42. The cam member 118has an outer surface that is eccentric with respect to the axis of thedrive shaft 42 so that the outer surface of the cam member 118 rotateseccentrically about the axis of the drive shaft 42 as the drive shaft 42rotates.

As shown in FIG. 2, a projection 120 on the cam member 118 engages inthe pocket 45 on the hub 44 so that the cam member 118 does not rotaterelative to the drive shaft 42 or relative to the gear 38. However, thecam member 118 is removable from the drive shaft 42 by sliding the cammember 118 off an end of the drive shaft 42. In this manner, the cammember 118 can be replaced if the cam member 118 becomes worn.Similarly, the cam member 118 can be interchanged with another cammember (not shown) having a different eccentric or cam configuration onits outer surface.

The orbital drive assembly also includes (see FIGS. 2-5) a cam follower122. The cam follower 122 includes a lower portion 126 that isselectively engageable with the outer surface of the cam member 118. Thecam follower 122 also includes head portion 130.

The cam follower 122 is supported (see FIG. 3) by a pin support member134 secured to the housing 14. Specifically, the cam follower 122 ispositioned within a pin support channel 138 defined by the supportmember 134. The cam follower 122 is supported by the support member 134so that the cam follower 122 is movable relative to the support member134 along the longitudinal axis of the cam follower 122. The channel 138substantially prevents the cam follower 122 from rotating or movinglaterally relative to the longitudinal axis of the cam follower 122.When the lower portion 126 of the cam follower 122 is engaged with therotating cam member 118, the cam follower 122 reciprocates along thelongitudinal axis of the cam follower 122.

The orbital drive assembly also includes (see FIGS. 2 and 4-5) a tubechassis 142 that is supported in the housing 14 for pivotal movementrelative to the housing 14. The tube chassis 142 is generallycylindrical and has a hollow inner portion for receiving the spindle 50.The spindle 50 is supported by the tube chassis 142 for reciprocatingmovement along the longitudinal axis of the tube chassis 142. The tubechassis 142 has a rear portion 144 and a forward flanged portion 146 anddefines (see FIGS. 2 and 6) a slot 150 through which the drive arm 86 ofthe primary wobble plate 78 extends to engage the spindle 50. Thecounterweight 70 is supported on the outer surface of the tube chassis142 for reciprocating movement relative to the tube chassis 142.

In the illustrated construction, the head portion 130 of the camfollower 122 engages the rear portion 144 of the tube chassis 142. Whenthe cam follower 122 reciprocates, the tube chassis 142 pivots relativeto the housing 14 about the forward flanged portion 146 (see FIG. 2) ofthe tube chassis 142. Because the tube chassis 142 is positioned betweenthe spindle 50 and the counterweight 70, the spindle 50 and thecounterweight 70 pivot with the tube chassis 142. The pivoting movementof the tube chassis 142 and the spindle 50 in combination with thereciprocation of the spindle 50 causes the saw blade 58 to move in anorbital path.

As shown in FIGS. 2 and 4-5, the tube chassis 142 extends through acentral opening 152 formed in the support member 134. The support member134 limits the lateral movement of the tube chassis 142. In otherconstructions (not shown), a limiting portion may be provided by bossesor guides formed on the inner portion of the housing 14 to limit thelateral movement of the tube chassis 142.

The reciprocating saw 10 also includes (see FIGS. 2 and 6) a sphericalbearing assembly to accommodate the pivotal movement of the spindle 50and the tube chassis 142 relative to the housing 14. The sphericalbearing assembly also seals an inner, forward portion 153 of the housing14 to prevent debris from entering the housing 14 and adverselyaffecting the operation of the reciprocating saw 10.

The spherical bearing assembly includes a split spherical sleeve 154captured between the forward flanged portion 146 of the tube chassis 142and the inner, forward portion 153 of the housing 14. The sphericalsleeve 154 has a spherical outer surface to accommodate pivotingmovement of the tube chassis 142 relative to the housing 14.

The spherical bearing assembly also includes a spherical bearing member158 positioned between the inner surface of the tube chassis 142 and theouter surface of the spindle 50. The bearing member 158 accommodatesreciprocation of the spindle 50 relative to the tube chassis 142. Thebearing member 158 also limits the forward movement of the spindle 50relative to the tube chassis 142 so that the spindle 50 is retainedwithin the tube chassis 142. An O-ring 162 (see FIG. 2) is positionedbetween the bearing member 158 and the inner surface of the forwardflanged portion 146 of the tube chassis 142.

The spherical bearing assembly also includes a forward seal 163sealingly engaging the spherical bearing member 158 and the spindle 50.A seal retainer plate 164 covers the seal 163 and a portion of thespherical bearing member 158. The seal retainer plate 164 has aspherical outer surface.

The spherical bearing assembly also includes a retaining member 166engaging the housing 14 and the seal retainer plate 164 to retain thespherical bearing assembly, the tube chassis 142 and the spindle 50within the housing 14. The spherical surface of the seal retainer plate164 engages the inner surface of the retaining member 166 to accommodatepivoting movement of the spindle 50 relative to the retaining member 166and relative to the housing 14.

The spherical bearing assembly improves the ease of manufacture andassembly of the reciprocating saw 10. To assemble this portion of thereciprocating saw 10, the bearing member 158 and the O-ring 162 are slidrearwardly into the tube chassis 142. The spindle 50 is slid forwardlythrough the tube chassis 142 and through the bearing member 158. Thetube chassis 142 is then positioned in the housing 14 and slid throughthe inner, forward portion 153 of the housing 14.

The forward seal 163 and the seal retainer plate 164 are slid rearwardlyonto the spindle 50 into engagement with the forward portion of thebearing member 158. The split spherical sleeve 154 is positioned aroundthe forward flanged portion 146 of the tube chassis 142, and the tubechassis 142 is slid rearwardly to capture the spherical sleeve 154.Finally, the retaining member 166 is locked into position against theseal retainer plate 164 to retain and seal the spherical bearingassembly, the tube chassis 142, and the spindle 50 within the housing14.

In other constructions (not shown), the spherical bearing assembly mayinclude a whole ring spherical sleeve rather than the split sphericalsleeve 154. In such a construction, the whole ring spherical sleeve ispositioned on the tube chassis 142, and the tube chassis 142 is slidrearwardly through the inner, forward portion 153 of the housing 14.

The reciprocating saw 10 also includes (see FIGS. 2-5) an orbitaladjustment assembly for adjusting the orbital path of the saw blade 58.In the illustrated construction, the orbital path of the saw blade 58 isadjusted by controlling or limiting the pivoting movement of the tubechassis 142 and the spindle 50.

The orbital adjustment assembly includes an orbital adjustment member170 supported by the housing 14 and the support member 134 forrotational movement about the rear portion 144 of the tube chassis 142.The adjustment member 170 has a generally cylindrical outer surfacedefining the rotational axis of the adjustment member 170. The supportmember 134 limits the downward movement of the adjustment member 170 andresists the downward force applied to the adjustment member 170 duringcutting operations.

The adjustment member 170 includes (see FIGS. 3-4) a cam surface 174having first, second and third cam portions 178, 182, and 184. Theadjustment member 170 is positioned adjacent to the cam follower 122 sothat portions of the cam surface 174 are selectively engageable with thehead portion 130 of the cam follower 122.

The orbital adjustment assembly also includes (see FIGS. 1-5) an orbitalrelease member 186 for rotating the adjustment member 170 relative tothe cam follower 122. Specifically, the release member 186 is secured tothe adjustment member 170 and is supported within the housing 14 forrotation about the axis of the adjustment member 170.

The release member or lever 186 includes (see FIGS. 1-4) amanually-operable portion 188 which extends through an opening 190 (seeFIGS. 1-2) in the upper portion 26 of the housing 14 so that themanually-operable portion 188 can be engaged by the operator from eitherside of the housing 14. In this manner, the operator can use either handto adjust the rotational position of the release member 186 andadjustment member 170. As explained more fully below, the release member186 is operable to move the adjustment member 170 between a first orfull-orbit position (shown in FIG. 4A), a second or reduced-orbitposition (shown in FIG. 4B), and a third or no-orbit position.

The release member 186 also includes a first detent portion (not shown)formed on the manually-operable portion 188. The first detent portionengages a second detent portion (not shown) formed on the housing 14when the release member 186 is in the first, second, or third positionto hold the release member 186 in that selected position.

The reciprocating saw 10 also includes (see FIGS. 1, 2, 8, and 9) anadjustable shoe assembly including (see FIGS. 1-2) a shoe plate 194having a surface for engaging a surface of a workpiece W. The shoe plate194 defines an aperture 198 through which the saw blade 58 isextendable. The aperture 198 is dimensioned to accommodate the orbitalpath of the saw blade 58.

The adjustable shoe assembly also includes (see FIGS. 1, 2, 8, and 9) ashoe support member 202 pivotally connected to the shoe plate 194. Theshoe support member 202 is movably supported by the housing 14 to adjustthe position of the shoe plate 194 relative to the housing 14.

A shoe retaining plate 206 is supported in a slot 210 (see FIG. 2)defined in the housing 14 to form a channel in which the shoe supportmember 202 is movable. The retaining plate 206 supports the shoe supportmember 202 along at least two walls (i.e., the bottom wall and a sidewall). In an alternative embodiment (see FIG. 8A), the retaining plate206 includes hardened wear surfaces provided by contact portions 212 toform a channel which supports the shoe support member 202 on all foursides.

The shoe support member 202 includes (see FIGS. 2, 8, and 9) a pluralityof pairs of teeth 214 spaced along the length of the shoe support member202. One tooth 214 of each pair is formed on each lateral side of theshoe support member 202.

As shown in FIGS. 1, 2 and 9, a rubber boot 216 covers and seals theforward portion of the housing 14 and the shoe retaining plate 206. Theboot 216 also provides an improved gripping surface for the operator.

The adjustable shoe assembly also includes a locking member 218pivotably supported by the housing 14. The locking member 218 isgenerally cylindrical but includes an axially-extending flat surface222. A shoe release lever 226 is pivotally supported on the lower,forward portion 22 of the housing 14 and is connected to the lockingmember 218 so that pivotal movement of the lever 226 causes pivotalmovement of the locking member 218. In this location, an operator canengage the lever 226 from either side of the housing 14 with eitherhand. A metal insert 228 is co-molded with the lever 226 to provideadditional strength to the lever 226.

The lever 226 is movable between a first or locked position (shown inFIG. 2) and a second or released position (shown in FIG. 9). In thelocked position (FIG. 2), the locking member 218 is pivoted so that thelocking member 218 engages the teeth 214. The rounded portion of thelocking member 218 engages the forward rounded surface of each of a pairof teeth 214, and the flat surface 222 engages the adjacent pair ofteeth 214. In this manner, the shoe support member 202 is substantiallyprevented from moving relative to the housing 14.

To adjust the position of the shoe plate 194 relative to the housing 14,the operator moves the lever 226 to the release position (FIG. 9). Asthe lever 226 is pivoted to the release position, the locking member 218is pivoted relative to the shoe support member 202. In the releaseposition (FIG. 9), the locking member 218 is pivoted so that the lockingmember 218 does not engage the teeth 214. The teeth 214 are movablebeneath the flat surface 222 of the locking member 218. With the lever226 maintained in the release position, the operator can adjust the shoeplate 194 relative to the housing 14 so that the shoe plate 194 is in anoptimum position for cutting.

Once the shoe plate 194 is in the desired position, the lever 226 ispivoted to the locked position (FIG. 2), and the operator performs thecutting operation with the reciprocating saw 10. During cuttingoperations, the lever 226 is normally grasped by the operator in thelocked position so that the locking member 218 will be maintained inthis locked position.

The adjustable shoe assembly also includes a biasing member (not shown)to normally bias the lever 226 toward the locked position. The spring ispreferably supported so that, as the lever 226 is moved to the releaseposition, the spring moves over-center to bias the lever 226 toward therelease position.

In operation of the reciprocating saw 10, the motor 30 is energized torotate the drive shaft 42. The wobble shaft 74 rotates with the driveshaft 42 causing the primary wobble plate 78 to reciprocate the spindle50 and causing the secondary wobble plate 82 to reciprocate thecounterweight 70. The saw blade 58 reciprocates with the spindle 50.

Based on the operator's selection of the position of the adjustmentmember 170, the orbital drive assembly selectively causes orbitalmovement of the saw blade 58. In the full-orbit position (FIG. 4A), thecam follower 122 engages the outer surface of the cam member 118throughout the rotation of the cam member 118. Engagement of the firstcam portion 178 with the head portion 130 does not disengage the lowerportion 126 of the cam follower 122 from the cam member 118. As aresult, as the cam member 118 rotates, the cam follower 122reciprocates, causing the tube chassis 142 and the spindle 50 to pivotas the spindle 50 reciprocates. This combination of reciprocatingmovement and pivoting movement causes the saw blade 58 to move in afull-orbit path defined by the cam configuration of the cam member 118.

In the reduced-orbit position (FIG. 4B), the second cam portion 182engages the head portion 130 to disengage the lower portion 126 of thecam follower 122 from the cam member 118 during at least a portion ofthe rotation of the cam member 118. As a result, the cam follower 122does not reciprocate during this portion of the rotation of the cammember 118. The tube chassis 142 and the spindle 50 are also thus notpivoted during this portion of the rotation of the cam member 118,limiting the orbital movement of the saw blade 58 to a reduced-orbitpath.

In the no-orbit position, the third cam portion 184 engages the headportion 130 to disengage the cam follower 122 from the cam member 118during the complete rotation of the cam member 118. As a result, the camfollower 122 does not reciprocate as the cam member 118 rotates, and thetube chassis 142 and the spindle 50 do not pivot. Thus, the saw blade 58reciprocates in a straight, no-orbit path.

In other constructions (not shown), the orbital adjustment assembly maybe operable to disengage the tube chassis 142 from the cam follower 122to limit the pivoting movement of the tube chassis 142 and the spindle50 and to thereby limit the orbital path of the saw blade 58. In yetother constructions (not shown), the cam surface 174 of the adjustmentmember 170 may be configured so that the orbital adjustment assembly hasonly a full-orbit condition and a no-orbit condition. Alternatively, thecam surface 174 may be configured so that the orbital adjustmentassembly is infinitely adjustable between the full-orbit condition andthe no-orbit condition.

The foregoing description of the present invention has been presentedfor purposes of illustration and description. Furthermore, thedescription is not intended to limit the invention to the form disclosedherein. Consequently, variations and modifications commensurate with theabove teachings, and the skill or knowledge of the relative art, arewithin the scope of the present invention. The embodiments describedherein are further intended to explain best modes known for practicingthe invention and to enable others skilled in the art to utilize theinvention in such, or other, embodiments and with various modificationsrequired by the particular applications or uses of the presentinvention. It is intended that the appended claims be construed toinclude alternative embodiments to the extent permitted by the priorart.

1. A reciprocating saw comprising: a housing; a motor supported by thehousing; a spindle movably supported by the housing, the spindle havingan end adapted to support a saw blade; a drive mechanism connectedbetween the motor and the spindle to reciprocally drive the spindlerelative to the housing upon operation of the motor; a shoe for engaginga surface of a workpiece; a shoe support member supporting the shoe, theshoe support member being movably supported by the housing; a lockingassembly operable to lock the shoe support member in a position relativeto the housing, the locking assembly including a locking memberengageable with the shoe support member, the locking member having afirst end and a second end; and a lever operable to move the lockingmember between a locked position, in which the locking member engagesthe shoe support member to lock the shoe support member in a positionrelative to the housing, and an unlocked condition, in which the shoesupport member is movable relative to the housing, the lever including afirst lever member formed of a moldable material and a second levermember formed of a metallic material, the second lever member beingmolded with the first lever member, the second lever member defining arecess, one of the first end and the second end of the locking memberengaging the recess.
 2. The reciprocating saw as set forth in claim 1wherein the second lever member defines a first recess and a secondrecess, the first end and the second end of the locking memberrespectively engaging the first recess and the second recess.
 3. Thereciprocating saw as set forth in claim 1 and further comprising aretainer member supported by the housing and defining a channel, theshoe support member being movable in the channel, wherein the retainermember defines a first opening and a second opening respectivelyreceiving the first end and the second end of the locking member.
 4. Areciprocating saw comprising: a housing including a first grip surfacefor an operator's first hand and a second grip surface for an operator'ssecond hand; a motor supported by the housing; a spindle movablysupported by the housing, the spindle having an end adapted to support asaw blade; a drive mechanism connected between the motor and the spindleto reciprocally drive the spindle relative to the housing upon operationof the motor; a shoe for engaging a surface of a workpiece; a shoesupport member supporting the shoe, the shoe support member beingmovably supported by the housing; a locking assembly operable to lockthe shoe support member in a position relative to the housing; a leverfor operating the locking assembly between a locked condition, in whichthe shoe support member is locked in a position relative to the housing,and an unlocked condition, in which the shoe support member is movablerelative to the housing, the lever being supported on the first gripsurface such that, during operation of said saw, the operator's firsthand engages the first grip surface and the lever and thereby maintainsthe lever in a locked position corresponding to the locked condition ofthe locking assembly; and a retainer member supported by the housing anddefining a channel, and wherein the shoe support member is movable inthe channel; wherein the locking assembly includes a locking memberengageable with the shoe support member to lock the shoe support memberin a position relative to the housing, the locking member including afirst end and a second end, and wherein the retainer member defines afirst opening and a second opening respectively receiving the first endand the second end of the locking member.
 5. A reciprocating sawcomprising: a housing; a motor supported by the housing; a spindlemovably supported by the housing, the spindle having an end adapted tosupport a saw blade; a drive mechanism connected between the motor andthe spindle to reciprocally drive the spindle relative to the housingupon operation of the motor; a shoe for engaging a surface of aworkpiece; a shoe support member supporting the shoe, the shoe supportmember being movably supported by the housing; a locking assemblyoperable to lock the shoe support member in a position relative to thehousing, the locking assembly including a locking member engageable withthe shoe support member, the locking member having a first end and asecond end; a lever operable to move the locking member between a lockedposition, in which the locking member engages the shoe support member tolock the shoe support member in a position relative to the housing, andan unlocked condition, in which the shoe support member is movablerelative to the housing, the lever engaging the first end and the secondend of the locking member, and a retainer member supported by thehousing and defining a channel, the shoe support member being movable inthe channel, wherein the retainer member defines a first opening and asecond opening respectively receiving the first end and the second endof the locking member.
 6. A reciprocating saw comprising: a housingincluding a first grip surface for an operator's first hand and a secondgrip surface for an operator's second hand; a motor supported by thehousing; a spindle movably supported by the housing, the spindle havingan end adapted to support a saw blade; a drive mechanism connectedbetween the motor and the spindle to reciprocally drive the spindlerelative to the housing upon operation of the motor; a shoe for engaginga surface of a workpiece; a shoe support member supporting the shoe, theshoe support member being movably supported by the housing; a lockingassembly operable to lock the shoe support member in a position relativeto the housing; a lever for operating the locking assembly between alocked condition, in which the shoe support member is locked in aposition relative to the housing, and an unlocked condition, in whichthe shoe support member is movable relative to the housing, the leverbeing supported on the first grip surface such that, during operation ofsaid saw, the operator's first hand engages the first grip surface andthe lever and thereby maintains the lever in a locked positioncorresponding to the locked condition of the locking assembly; and aretainer member supported by the housing and defining a channel, whereinthe shoe support member is movable in the channel; and wherein thehousing defines a slot, the retainer member being supported in the slot.7. The reciprocating saw as set forth in claim 6 wherein the shoesupport member has a bottom wall and at least one side wall extendingfrom the bottom wall, and wherein the retainer member supports the shoesupport member along the bottom wall and along the side wall.
 8. Thereciprocating saw as set forth in claim 7 wherein the shoe supportmember has an upper surface, and wherein a portion of the retainermember engages the upper surface.
 9. A reciprocating saw comprising: ahousing; a motor supported by the housing; a spindle movably supportedby the housing, the spindle having an end adapted to support a sawblade; a drive mechanism connected between the motor and the spindle toreciprocally drive the spindle relative to the housing upon operation ofthe motor; a shoe for engaging a surface of a workpiece; a shoe supportmember supporting the shoe, the shoe support member being movablysupported by the housing; a locking assembly operable to lock the shoesupport member in a position relative to the housing, the lockingassembly including a locking member engageable with the shoe supportmember, the locking member having a first end and a second end; and alever operable to move the locking member between a locked position, inwhich the locking member engages the shoe support member to lock theshoe support member in a position relative to the housing, and anunlocked position, in which the shoe support member is movable relativeto the housing, the lever engaging the first end and the second end ofthe locking member; wherein the lever includes a first lever memberformed of a moldable material and a second lever member formed of ametallic material, the second lever member being molded with the firstlever member, the second lever member defining a recess, one of thefirst end and the second end of the locking member engaging the recess.10. The reciprocating saw as set forth in claim 9 wherein the secondlever member defines a first recess and a second recess, the first endand the second end of the locking member respectively engaging the firstrecess and the second recess.
 11. The reciprocating saw as set forth inclaim 9 wherein the locking member is pivotable between the lockedposition and the unlocked position.
 12. A reciprocating saw comprising:a housing including a first grip surface for an operator's first handand a second grip surface for an operator's second hand; a motorsupported by the housing; a spindle movably supported by the housing,the spindle having an end adapted to support a saw blade; a drivemechanism connected between the motor and the spindle to reciprocallydrive the spindle relative to the housing upon operation of the motor; ashoe for engaging a surface of a workpiece; a shoe support membersupporting the shoe, the shoe support member being movably supported bythe housing; a locking assembly operable to lock the shoe support memberin a position relative to the housing; and a lever for operating thelocking assembly between a locked condition, in which the shoe supportmember is locked in a position relative to the housing, and an unlockedcondition, in which the shoe support member is movable relative to thehousing, the lever being supported on the first grip surface such that,during operation of said saw, the operator's first hand engages thefirst grip surface and the lever and thereby maintains the lever in alocked position corresponding to the locked condition of the lockingassembly; wherein the locking assembly includes a locking memberengageable with the shoe support member, and wherein the lever isoperable to move the locking member between a locked position, in whichthe locking member engages the shoe support member to lock the shoesupport member in a position relative to the housing, and an unlockedposition, in which the shoe support member is movable relative to thehousing; wherein the locking member has a first end and a second end,and wherein the lever engages the first end and the second end of thelocking member; wherein the lever includes a first lever member formedof a moldable material and a second lever member formed of a metallicmaterial, the second lever member being molded with the first levermember, the second lever member defining a recess, one of the first endand the second end of the locking member engaging the recess.
 13. Thereciprocating saw as set forth in claim 12 wherein the second levermember defines a first recess and a second recess, the first end and thesecond end of the locking member respectively engaging the first recessand the second recess.
 14. The reciprocating saw as set forth in claim12 wherein the housing has an upper portion, a lower portion, andopposed side portions, and wherein the lever is operable from the lowerportion of the housing.
 15. The reciprocating saw as set forth in claim12 wherein the first grip surface is selectively engageable by one ofthe operator's first hand and the operator's second hand, and whereinthe lever is operable by the one of the operator's first hand and theoperator's second hand engaging the first grip surface.
 16. Thereciprocating saw as set forth in claim 12 wherein the shoe supportmember defines therealong a plurality of teeth, wherein, in the lockedposition, the locking member engages the teeth so that the shoe supportmember is locked in a position relative to the housing, and wherein, inthe unlocked position, the locking member does not engage the teeth andthe shoe support member is movable relative to the housing.
 17. Thereciprocating saw as set forth in claim 12 wherein the locking member ispivotable between the locked position and the unlocked position.